US9698490B2 - Injection moldable cone radiator sub-reflector assembly - Google Patents

Injection moldable cone radiator sub-reflector assembly Download PDF

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Publication number
US9698490B2
US9698490B2 US13/795,274 US201313795274A US9698490B2 US 9698490 B2 US9698490 B2 US 9698490B2 US 201313795274 A US201313795274 A US 201313795274A US 9698490 B2 US9698490 B2 US 9698490B2
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sub
reflector
longitudinal
dielectric block
unitary dielectric
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US13/795,274
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US20130271349A1 (en
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Alastair Wright
John Curran
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Outdoor Wireless Networks LLC
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Commscope Technologies LLC
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Priority claimed from US13/448,995 external-priority patent/US9105981B2/en
Assigned to ANDREW LLC reassignment ANDREW LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CURRAN, JOHN, WRIGHT, ALASTAIR
Priority to US13/795,274 priority Critical patent/US9698490B2/en
Application filed by Commscope Technologies LLC filed Critical Commscope Technologies LLC
Priority to PCT/US2013/036689 priority patent/WO2013158584A1/en
Priority to EP13777517.7A priority patent/EP2839538B1/en
Priority to IN7881DEN2014 priority patent/IN2014DN07881A/en
Priority to CN201380017752.2A priority patent/CN104205497B/zh
Publication of US20130271349A1 publication Critical patent/US20130271349A1/en
Assigned to COMMSCOPE TECHNOLOGIES LLC reassignment COMMSCOPE TECHNOLOGIES LLC CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: ANDREW LLC
Assigned to WILMINGTON TRUST, NATIONAL ASSOCIATION, AS COLLATERAL AGENT reassignment WILMINGTON TRUST, NATIONAL ASSOCIATION, AS COLLATERAL AGENT SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ALLEN TELECOM LLC, COMMSCOPE TECHNOLOGIES LLC, COMMSCOPE, INC. OF NORTH CAROLINA, REDWOOD SYSTEMS, INC.
Assigned to ALLEN TELECOM LLC, COMMSCOPE TECHNOLOGIES LLC, COMMSCOPE, INC. OF NORTH CAROLINA, REDWOOD SYSTEMS, INC. reassignment ALLEN TELECOM LLC RELEASE OF SECURITY INTEREST PATENTS (RELEASES RF 036201/0283) Assignors: WILMINGTON TRUST, NATIONAL ASSOCIATION
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Assigned to JPMORGAN CHASE BANK, N.A. reassignment JPMORGAN CHASE BANK, N.A. TERM LOAN SECURITY AGREEMENT Assignors: ARRIS ENTERPRISES LLC, ARRIS SOLUTIONS, INC., ARRIS TECHNOLOGY, INC., COMMSCOPE TECHNOLOGIES LLC, COMMSCOPE, INC. OF NORTH CAROLINA, RUCKUS WIRELESS, INC.
Assigned to WILMINGTON TRUST, NATIONAL ASSOCIATION, AS COLLATERAL AGENT reassignment WILMINGTON TRUST, NATIONAL ASSOCIATION, AS COLLATERAL AGENT PATENT SECURITY AGREEMENT Assignors: COMMSCOPE TECHNOLOGIES LLC
Assigned to WILMINGTON TRUST reassignment WILMINGTON TRUST SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ARRIS ENTERPRISES LLC, ARRIS SOLUTIONS, INC., COMMSCOPE TECHNOLOGIES LLC, COMMSCOPE, INC. OF NORTH CAROLINA, RUCKUS WIRELESS, INC.
Assigned to Outdoor Wireless Networks LLC reassignment Outdoor Wireless Networks LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: COMMSCOPE TECHNOLOGIES LLC
Assigned to JPMORGAN CHASE BANK, N.A., AS COLLATERAL AGENT reassignment JPMORGAN CHASE BANK, N.A., AS COLLATERAL AGENT PATENT SECURITY AGREEMENT (ABL) Assignors: Outdoor Wireless Networks LLC
Assigned to JPMORGAN CHASE BANK, N.A., AS COLLATERAL AGENT reassignment JPMORGAN CHASE BANK, N.A., AS COLLATERAL AGENT PATENT SECURITY AGREEMENT (TERM) Assignors: Outdoor Wireless Networks LLC
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01Q—ANTENNAS, i.e. RADIO AERIALS
    • H01Q15/00—Devices for reflection, refraction, diffraction or polarisation of waves radiated from an antenna, e.g. quasi-optical devices
    • H01Q15/14—Reflecting surfaces; Equivalent structures
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01Q—ANTENNAS, i.e. RADIO AERIALS
    • H01Q19/00—Combinations of primary active antenna elements and units with secondary devices, e.g. with quasi-optical devices, for giving the antenna a desired directional characteristic
    • H01Q19/10—Combinations of primary active antenna elements and units with secondary devices, e.g. with quasi-optical devices, for giving the antenna a desired directional characteristic using reflecting surfaces
    • H01Q19/18—Combinations of primary active antenna elements and units with secondary devices, e.g. with quasi-optical devices, for giving the antenna a desired directional characteristic using reflecting surfaces having two or more spaced reflecting surfaces
    • H01Q19/19—Combinations of primary active antenna elements and units with secondary devices, e.g. with quasi-optical devices, for giving the antenna a desired directional characteristic using reflecting surfaces having two or more spaced reflecting surfaces comprising one main concave reflecting surface associated with an auxiliary reflecting surface
    • H01Q19/193—Combinations of primary active antenna elements and units with secondary devices, e.g. with quasi-optical devices, for giving the antenna a desired directional characteristic using reflecting surfaces having two or more spaced reflecting surfaces comprising one main concave reflecting surface associated with an auxiliary reflecting surface with feed supported subreflector

Definitions

  • This invention relates to a microwave dual reflector antenna. More particularly, the invention provides a self supported feed cone radiator for such antennas suitable for cost efficient manufacture via injection molding.
  • Dual reflector antennas employing self-supported feed direct a signal incident on the main reflector onto a sub-reflector mounted adjacent to the focal region of the main reflector, which in turn directs the signal into a waveguide transmission line typically via a feed horn or aperture to the first stage of a receiver.
  • the dual reflector antenna is used to transmit a signal, the signals travel from the last stage of the transmitter system, via the waveguide, to the feed aperture, sub-reflector, and main reflector to free space.
  • the electrical performance of a reflector antenna is typically characterized by its gain, radiation pattern, cross-polarization and return loss performance—efficient gain, radiation pattern and cross-polarization characteristics are essential for efficient microwave link planning and coordination, whilst a good return loss is necessary for efficient radio operation.
  • Deep dish reflectors are reflector dishes wherein the ratio of the reflector focal length (F) to reflector diameter (D) is made less than or equal to 0.25 (as opposed to an F/D of 0.35 typically found in more conventional dish designs).
  • An example of a dielectric cone feed sub-reflector assembly configured for use with a deep dish reflector is disclosed in commonly owned U.S. Pat. No. 6,919,855, titled “Tuned Perturbation Cone Feed for Reflector Antenna” issued Jul. 19, 2005 to Hills, hereby incorporated by reference in its entirety.
  • 6,919,855 utilizes a dielectric block cone feed with a sub-reflector surface and a leading cone surface having a plurality of downward angled non-periodic perturbations concentric about a longitudinal axis of the dielectric block.
  • the plurality of angled features and/or steps in the dielectric block requires complex machine tool manufacturing procedures which may increase the overall manufacturing cost.
  • FIG. 1 is a schematic cross-section cut-away side isometric view of an exemplary injection moldable dielectric cone radiator assembly.
  • FIG. 2 is a schematic front view of the injection moldable dielectric cone radiator assembly of FIG. 1 .
  • FIG. 3 is a schematic cut-away side view of the injection moldable dielectric cone radiator assembly of FIG. 1 , taken along line A-A of FIG. 2 .
  • FIG. 4 is a schematic cross-section cut-away side isometric view of an alternative exemplary injection moldable dielectric cone radiator assembly, with a separate sub-reflector disc.
  • FIG. 5 is a schematic front view of the injection moldable dielectric cone radiator assembly of FIG. 4 .
  • FIG. 6 is a schematic cut-away side view of the injection moldable dielectric cone radiator assembly of FIG. 4 , taken along line A-A of FIG. 5 .
  • FIG. 7 is a schematic cross-section cut-away isometric view of an alternative dielectric block configuration.
  • FIG. 8 is distal end view of the dielectric block of FIG. 7 , with a sub-reflector coupled to the distal end.
  • FIG. 9 is a schematic side cut-away close-up view of the dielectric block and sub-reflector of FIG. 8 , taken along line A-A of FIG. 8 .
  • the increased size may create issues with the setting of the dielectric polymer material, such as voids, cracks, surface sink, dimensional bends and/or sagging. Further, where the designs utilize features that inhibit mold separation, such as overhanging and/or close proximity opposing edges, the required mold, if possible at all, may become too complex to be cost effective.
  • a cone radiator sub-reflector assembly 1 may be configured to couple with the end of a feed boom waveguide at a waveguide transition portion 5 of a unitary dielectric block 10 which supports a sub-reflector 15 at the distal end 20 .
  • the sub-reflector 15 and a supporting subreflector support portion 30 are provided with an enlarged diameter for reduction of sub-reflector spill-over.
  • a dielectric radiator portion 25 is situated between the waveguide transition portion 5 and the sub-reflector support portion 30 .
  • a plurality of corrugations are provided along the outer diameter of the dielectric radiator portion as radial grooves 35 .
  • the plurality of grooves is two radial grooves 35 .
  • a distal groove 40 of the dielectric radiator portion 25 may be provided with a distal sidewall 45 that initiates the sub-reflector support portion 30 .
  • the grooves 40 may be provided with a taper that increases the groove width towards the outer diameter of the dielectric radiator portion 25 .
  • the waveguide transition portion 5 of the sub-reflector assembly 1 may be adapted to match a desired circular waveguide internal diameter so that the sub-reflector assembly 1 may be fitted into and retained by the waveguide end that supports the sub-reflector assembly 1 within the dish reflector of the reflector antenna proximate a focal point of the dish reflector.
  • the waveguide transition portion 5 may insert into the waveguide 3 until the end of the waveguide abuts a shoulder 55 of the waveguide transition portion 5 .
  • the shoulder 55 may be dimensioned to space the dielectric radiator portion 25 away from the waveguide end.
  • One or more step(s) 60 at the proximal end 65 of the waveguide transition portion 5 may be applied to a lens bore 70 of the dielectric block 10 to form an inverted impedance transformer 75 for impedance matching purposes between the waveguide and the dielectric material of the dielectric block 10 .
  • the lens bore 70 extends from the proximal end 65 of the dielectric block 10 towards the distal end 20 of the dielectric block 10 at least to the sub-reflector support portion 30 .
  • a direct path between the waveguide 3 and the dielectric radiator portion 25 is formed, enabling tuning of the radiation pattern emitted therethrough, for example, via the depth applied to the radial grooves 35 and/or diameter of the dielectric radiator portion 25 .
  • the radial grooves 35 extend radially inward to a diameter less than an inner diameter of the end of the waveguide.
  • the dielectric radiator portion 25 in combination with the lens bore 70 therethrough, creates a dielectric lens effect in which the dimensions of the dielectric radiator portion 25 enhances a primary radiation pattern projected through the dielectric radiator portion 25 to/from the sub-reflector 15 from/to the reflector dish that the sub reflector assembly 1 is mounted within, thereby assisting the shaping of the RF radiation pattern of the sub-reflector assembly 1 and reducing the diameter of sub-reflector 15 .
  • the lens bore 70 may be provided extending entirely through the dielectric block 10 , between the proximal end 65 and the distal end 20 .
  • sub-reflector 15 may be formed by applying a metallic deposition, film, sheet or other RF reflective coating to the distal end 20 of the dielectric block 10 .
  • the sub-reflector 15 may be formed separately, for example as a metal disk 80 which seats upon the distal end of the dielectric block 10 .
  • the disk 80 may include a key portion 85 that keys with the lens bore 70 to position the sub-reflector 15 coaxially upon the distal end 20 of the dielectric block 10 .
  • the centerpoint of such a circle is generally the point from which it is farthest to an edge of the dielectric block 10 , the maximum material thickness.
  • the centerpoint is the location where during injection molding of the dielectric block 10 , the dielectric material will typically solidify/set last.
  • the maximum material thickness occurs in the embodiments of FIGS. 3 and 6 located between the distal sidewall 45 and the distal end 20 .
  • the maximum material thickness of prior embodiments of monolithic dielectric block cones is much larger, typically at least the entire inner diameter of the waveguide end.
  • the combination of the lens bore 70 and the deepened radial grooves 35 may significantly reduce the maximum material thickness of the dielectric block 10 , enabling the manufacture of the dielectric block 10 via injection molding with reduced voids, cracks, surface sink, dimensional bends and/or sagging defects.
  • the dielectric block 10 may be manufactured by casting and/or machining, which methods may similarly benefit from the common angle of mold/tool separation/approach, shallower edge angles and/or number of surface transitions required.
  • the dielectric block 10 may be alternatively formed with longitudinal grooves instead of radial grooves to further simplify manufacture by injection molding with reduced maximum material thickness. As shown for example in FIGS. 7 and 9 , a plurality of longitudinal grooves 90 and longitudinal ribs 95 therebetween may be applied coaxial with a longitudinal axis of the dielectric block 10 .
  • the waveguide transition portion 5 and sub-reflector support portion 30 are characterized as inner and outer coaxial portions, respectively, an outer diameter of the waveguide transition portion 5 dimensioned to seat, for example, within the inner diameter of the waveguide for coupling therewith and portions between these surfaces and a periphery of the dielectric block 10 are operative as the sub-reflector support portion 30 .
  • the longitudinal grooves 90 are each open to the proximal end 65 of the dielectric block 10 .
  • mold separation where there are no overhanging features present between the longitudinal grooves 90 and the proximal end 65 , may be along the longitudinal axis of the dielectric block 10 , enabling a two part mold and localizing any mold flash that may occur to the periphery of the dielectric block 10 , instead of a potentially difficult to remove longitudinal flash along each of the grooves that may be present in the dielectric block 10 of the radial groove embodiments of FIGS. 3 and 6 .
  • the longitudinal grooves 90 may be provided with a taper for ease of mold separation.
  • a longitudinal extent of the longitudinal rib(s) 95 and/or longitudinal groove(s) 90 of the wave guide transition portion 5 may be selected to provide an impedance transformer 75 for impedance matching purposes between the waveguide and the dielectric material of the dielectric block 10 .
  • a longitudinal extent of the longitudinal rib(s) 95 of the sub-reflector support portion 30 toward the proximal end 65 of the dielectric block 10 shortens between an inner diameter and a periphery of the sub-reflector support portion 30 .
  • a leading edge of the longitudinal ribs of the sub-reflector support portion may be angled to form a generally conical surface with a maximum diameter toward the distal end 20 , the plurality of longitudinal ribs 95 together forming a generally conical surface profile for the sub-reflector support portion.
  • the longitudinal ribs 95 may be dimensioned to create alternative surface profiles as desired for electrical performance including, for example, a staggered or planar surface profile.
  • a depth of the longitudinal grooves 90 may be selected to obtain a balance between electrical performance, necessary strength and maximum material thickness, for example where the maximum material thickness M of the dielectric block 10 occurs between a distal end 20 of a pair of the longitudinal grooves 90 and the sub-reflector 15 .
  • the sub-reflector 15 may be provided as a metal coating upon the distal end 20 of the dielectric block 10 or as a separate metallic disc coupled to the distal end 20 of the dielectric block 10 .
  • the longitudinal axis mold separation further enables the sub-reflector 15 to be fitted within the dielectric block mold and coupled there to by the injection molding.
  • the present invention brings to the art a sub-reflector assembly 1 for a reflector antenna with the potential for significant manufacturing cost efficiencies.
  • the sub-reflector assembly 1 according to the invention are strong, lightweight and may be repeatedly cost efficiently manufactured with a very high level of precision via, for example, injection molding technology.

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  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Aerials With Secondary Devices (AREA)
  • Waveguide Aerials (AREA)
US13/795,274 2012-04-17 2013-03-12 Injection moldable cone radiator sub-reflector assembly Active 2033-03-30 US9698490B2 (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
US13/795,274 US9698490B2 (en) 2012-04-17 2013-03-12 Injection moldable cone radiator sub-reflector assembly
PCT/US2013/036689 WO2013158584A1 (en) 2012-04-17 2013-04-16 Injection moldable cone radiator sub-reflector assembly
CN201380017752.2A CN104205497B (zh) 2012-04-17 2013-04-16 可注射成型的锥形辐射器次反射器组件
EP13777517.7A EP2839538B1 (en) 2012-04-17 2013-04-16 Injection moldable cone radiator sub-reflector assembly
IN7881DEN2014 IN2014DN07881A (zh) 2012-04-17 2013-04-16

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US13/448,995 US9105981B2 (en) 2012-04-17 2012-04-17 Dielectric lens cone radiator sub-reflector assembly
US13/795,274 US9698490B2 (en) 2012-04-17 2013-03-12 Injection moldable cone radiator sub-reflector assembly

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
US13/448,995 Continuation-In-Part US9105981B2 (en) 2012-04-17 2012-04-17 Dielectric lens cone radiator sub-reflector assembly

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US20130271349A1 US20130271349A1 (en) 2013-10-17
US9698490B2 true US9698490B2 (en) 2017-07-04

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EP (1) EP2839538B1 (zh)
CN (1) CN104205497B (zh)
IN (1) IN2014DN07881A (zh)
WO (1) WO2013158584A1 (zh)

Cited By (1)

* Cited by examiner, † Cited by third party
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US20240145935A1 (en) * 2022-10-31 2024-05-02 Agency For Defense Development Antenna apparatus

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